Inductor assembly support structure

Abstract

A vehicle is provided with a transmission and an inductor assembly that is mounted within a chamber of the transmission. The inductor assembly includes a coil, a core and an insulator having first and second portions that are oriented toward each other. Each portion includes a base, a support extending from the base, and a spool extending transversely from the support to engage the other portion. Each spool includes an external surface for supporting the coil and a cavity extending therethrough for receiving the core.

What is claimed is: 
     
       1. A vehicle comprising:
 a transmission defining a chamber and including a pair of sidewalls that project into the chamber and define a partially encircled recess therebetween; and 
 an inductor assembly mounted between the sidewalls and including an insulator having first and second portions oriented toward each other, each with a base disposed adjacent to one of the sidewalls, a support extending from the base, and a spool extending transversely from the support to engage the other portion, each spool having an external surface for supporting a coil and a cavity extending therethrough for receiving a core, wherein the insulator supports the coil and the core such that the coil is exposed to direct contact with fluid within the chamber to cool the coil. 
 
     
     
       2. The vehicle of  claim 1  wherein the base is formed with at least one aperture extending therethrough for receiving a fastener and for mounting the inductor assembly to the transmission. 
     
     
       3. The vehicle of  claim 1  wherein the core further comprises a first end, a second end and first and second legs for interconnecting the first end to the second end to collectively form a ring, wherein the spool further comprises a first spool and a second spool, and wherein each spool is sized for receiving one of the first and second legs therethrough. 
     
     
       4. The vehicle of  claim 3  wherein each of the first and second legs further comprises a plurality of core elements with insulative spacers disposed between adjacent core elements to define air gaps. 
     
     
       5. The vehicle of  claim 1  wherein the core further comprises at least two apertures formed therethrough and wherein each aperture is sized for receiving a fastener for mounting the inductor assembly to the wall of the transmission. 
     
     
       6. The vehicle of  claim 1  further comprising a spring disposed between one of the sidewalls and a first end of the core and imparting a longitudinal force upon the inductor assembly, wherein a second end of the core oriented longitudinally opposite the first end engages the other of the sidewalls such that the longitudinal force retains the inductor assembly within the recess for mounting the inductor assembly to the transmission. 
     
     
       7. The vehicle of  claim 6  further comprising at least one plate that extends across the recess and over a portion of the insulator for retaining the inductor assembly within the recess. 
     
     
       8. The vehicle of  claim 1 , wherein the insulative material further comprises potting compound. 
     
     
       9. The vehicle of  claim 1 , wherein the inductor assembly does not include a cooling plate. 
     
     
       10. A vehicle comprising:
 a transmission including a pair of sidewalls that project into a chamber defined by the transmission to define a partially encircled recess therebetween; 
 a coil; 
 a core; and 
 an insulator disposed between the sidewalls and having first and second portions, each with:
 a base disposed adjacent to one of the sidewalls, 
 a support extending from the base, and 
 a spool extending transversely from the support to engage the other portion, each with an external surface to support the coil and a cavity to receive the core, wherein the insulator supports the coil and the core such that exposed surface area portions of the coil are exposed to direct contact with fluid within the transmission to cool the coil. 
 
 
     
     
       11. The vehicle of  claim 10  wherein the exposed surface area portions of the coil are not covered by insulative material. 
     
     
       12. The vehicle of  claim 10  wherein the core further comprises a first end, a second end and first and second legs for interconnecting the first end to the second end to collectively form a ring, wherein the spool further comprises a first spool and a second spool, and wherein each spool is sized for receiving one of the first and second legs therethrough. 
     
     
       13. The vehicle of  claim 12  wherein each of the first and second legs further comprises a plurality of core elements with insulative spacers disposed between adjacent core elements to define air gaps. 
     
     
       14. The vehicle of  claim 10  wherein the core further comprises at least two apertures formed therethrough and wherein each aperture is sized for receiving a fastener for mounting the insulator to the wall of the transmission. 
     
     
       15. A vehicle comprising:
 a transmission defining a chamber and including a pair of sidewalls that project from a wall of the transmission and define a partially encircled recess therebetween; 
 a coil; 
 a core; and 
 an insulator disposed between the sidewalls within the recess and adapted to support the coil and the core such that 
 portions of the coil are exposed to direct contact with fluid within the chamber to cool the coil. 
 
     
     
       16. The vehicle of  claim 15 , wherein the insulator further comprises first and second portions, each with:
 a base to be disposed adjacent one of the sidewalls; 
 a support extending from the base; and 
 a spool extending transversely from the support to engage the other portion and defining a cavity for receiving the core.